Automated fastener insert installation system for composite panels

ABSTRACT

An automated fastener insert installation system for composite panels is provided. A first module receives and secures a composite panel with respect to an origin of a first coordinate system, wherein the composite panel has opposed major surfaces and defines an insert-receiving orifice extending through one of the major surfaces, and is secured such that one of the major surfaces is externally accessible. A second module engages each of a plurality of fastener inserts with an installation aide. Third module determines a configuration of the orifice defined by the composite panel, selects a corresponding one of the fastener inserts engaged with the installation aide, inserts the selected fastener insert into the orifice, and dispenses an adhesive material through the installation aide and into the orifice about selected fastener insert such that the adhesive material secures the selected fastener insert within the orifice. Associated systems are also provided.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a divisional of U.S. patent application Ser.No. 14/949,278, filed Nov. 23, 2015, the disclosure of which isincorporated herein by reference in its entirety.

BACKGROUND Field of the Disclosure

The present disclosure is directed to an automated fastener insertinstallation system for composite panels.

Description of Related Art

Composite panels, such as honeycomb-cored sheets, often cannot havemechanical fasteners directly affixed thereto. In some instances whereinsuch a composite panel may require a mechanical fastener to be affixedthereto, a fastener-receiving insert may first be installed in andsecured to the composite panel, and the mechanical fastener is thenengaged with the insert. In this manner, the mechanical fastener can beused with the installed insert to secure the composite panel to othercomposite panels or structures.

However, such inserts often require a high degree of precision andconformance to tolerances when installed in the composite panel in orderto provide an effective anchor for the mechanical fastener. For example,there may be several configurations or sizes of inserts, and each insertrequires that the insertion orifice in the composite panel becorrespondingly configured or sized. It is not desirable to install aninsert configured for a through-hole orifice in a blind-hole-configuredorifice, and vice versa. Moreover, insert-receiving-orifice defined bythe composite panel must have an appropriate diameter and/orlength/depth corresponding to the diameter and/or length of the insertreceived thereby. Further, the inserts may have to be installed so as tobe as close to flush or coplanar with the outer surface of the compositepanel as possible, in order to provide optimal interaction with themechanical fastener and structural integrity of the assembled endproduct. In addition, such an insert may often be installed in thecomposite panel using an adhesive material (i.e., a special purposetwo-part potting compound). However, such a special purpose pottingcompound typically requires careful handling, but also has a limitedtime in which it can be applied once mixed or actuated. Also, such apotting compound cures and hardens, once applied, which may limitre-work opportunities in the event of an imprecise insert installationprocedure. In some instances, one imprecise insert installation in acomposite panel will, at a minimum, require labor intensive rework, andmay cause that composite panel to be designated as scrap.

As such, there exists a need for a system and method for installingfastener inserts in composite panels that addresses issues in aconventional process.

SUMMARY OF THE DISCLOSURE

The above and other needs are met by aspects of the present disclosurewhich, in one aspect, provides an automated fastener insert installationsystem for use in a composite panel fastener insert installationprocess. Such a system comprises an analysis device configured todetermine a configuration or a size of the insert-receiving orificedefined by and extending through a major surface of a composite panel. Amanipulation device is in communication with the analysis device and isconfigured to select and retrieve one of a plurality of fastener insertsengaged with an installation aide, in response to the configuration orthe size of the insert-receiving orifice determined by the analysisdevice, and to insert the selected fastener insert into theinsert-receiving orifice such that the installation aide engages themajor surface of the composite panel. An adhesive dispenser device isconfigured to dispense an adhesive material through adhesive applicationorifices defined by the installation aide and the selected fastenerinsert, and into the insert-receiving orifice about selected fastenerinsert, such that the adhesive material interacts with the selectedfastener insert and the composite panel defining the insert-receivingorifice so as to secure the selected fastener insert within theinsert-receiving orifice.

Another aspect of the present disclosure provides an automated fastenerinsert installation system for use in a composite panel fastener insertinstallation process. Such a system comprises an adhesive materialpreparation system, including a mixing device configured to mix andactuate the adhesive material in an adhesive material kit, and amanipulation device configured to direct the adhesive material kit tothe mixing device and to direct the adhesive material kit having themixed and actuated adhesive material therein from the mixing device fordispensation.

The aspects, functions and advantages discussed herein may be achievedindependently in various example implementations/aspects or may becombined in yet other example implementations/aspects, further detailsof which may be seen with reference to the following description anddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described the disclosure in general terms, reference willnow be made to the accompanying drawings, which are not necessarilydrawn to scale, and wherein:

FIG. 1 schematically illustrates a fastener insert installation system,according to one aspect of the present disclosure;

FIG. 2 schematically illustrates a panel handling system and a fastenerinsert installation system, according to one aspect of the presentdisclosure;

FIG. 3 schematically illustrates a fastener insert assembly system,according to one aspect of the present disclosure;

FIG. 4 schematically illustrates an adhesive material preparationsystem, according to one aspect of the present disclosure;

FIG. 5A schematically illustrates an example configuration of a blindhole fastener insert, according to one aspect of the present disclosure;

FIG. 5B schematically illustrates an example configuration of athrough-hole fastener insert, according to one aspect of the presentdisclosure; and

FIG. 6 schematically illustrates an adhesive material kit, according toone aspect of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allaspects of the disclosure are shown. Indeed, the disclosure may beembodied in many different forms and should not be construed as limitedto the aspects set forth herein; rather, these aspects are provided sothat this disclosure will be thorough and complete, will fully conveythe scope of the disclosure to those skilled in the art, and willsatisfy applicable legal requirements. Like numbers refer to likeelements throughout. As used in this specification and the claims, thesingular forms “a,” “an,” and “the” include plural referents unless thecontext clearly dictates otherwise.

As schematically illustrated in FIG. 1, one aspect of the presentdisclosure provides an automated fastener insert installation system100, which may be particularly applicable to composite panels, such as,for example, a honeycomb-cored sheet. Such a system 100 may generallycomprise a panel handling module or system 300, an adhesive materialpreparation module or system 500, a fastener insert assembly module orsystem 700, and a fastener insert installation module or system 900,configured to cooperate to automatically insert a fastener insert 50(see, e.g., FIGS. 5A and 5B) into a composite panel 75.

The panel handling module or system 300 as shown, for example, in FIG.2, is configured to receive and secure the composite panel 75 withrespect to an origin 1100 of a first coordinate system 1200. Thecomposite panel 75 is generally in the form of a sheet, and has opposedmajor surfaces 75A, 75B (see, e.g., FIGS. 5A and 5B). In some instances,the fastener insert installation system 100 may be a downstream processreceiving a previously-processed composite panel 75. That is, in aprevious upstream process, the composite panel 75 may be processedthrough a milling machine/device (not shown) configured to form at leastone insert-receiving orifice 25 in the composite panel 75, with the atleast one orifice 25 extending through one of the major surfaces 75A,75B of the composite panel 75.

The panel handling module 300 includes opposing frame members 320, 340,wherein at least one of the frame members 320, 340 is movable (i.e.,pivotable) with respect to the other frame member. With the framemember(s) 320, 340 moved to be in an open position with respect to eachother, the panel handling module 300 is configured to receive thecomposite panel 75 therebetween. If necessary or desired, either or bothframe members 320, 340 may have adjustable supports 360 engagedtherewith, wherein the supports 360 may be moved or re-arranged, asnecessary to assist in supporting composite panels having differentconfigurations. The frame members 320, 340 may then be moved to a closedposition with respect to each other to thereby secure the compositepanel 75 therebetween.

According to aspects of the disclosure, the composite panel 75 may besecured by the frame members 320, 340, and the adjustable supports 360,if implemented, of the panel handling module 300, such that one of themajor surfaces 75A, 75B of the composite panel 75 is externallyaccessible. Moreover, the frame members 320, 340, and the adjustablesupports 360, if implemented, are configured and arranged such that theat least one insert-receiving orifice 25 defined by the composite panel75 is externally accessible. In some instances, the composite panel 75may be configured to receive fastener insert(s) 50 through both majorsurfaces 75A, 75B of the composite panel 75. That is, both majorsurfaces 75A, 75B may define at least one insert-receiving orifice 25.In such instances, the frame members 320, 340 may be collectivelymounted so as to be rotatable over at least 180 degrees, such that bothmajor surfaces 75A, 75B of the composite panel 75 are externallyaccessible. In this manner, the frame members 320, 340 may be configuredto secure the composite panel 75 in one orientation such that one of themajor surfaces 75A, 75B is externally accessible for installation ofappropriate fastener inserts 50 therein, wherein the frame members 320,340 can then be collectively rotated 180 degrees such that the other ofthe major surfaces 75A, 75B is externally accessible such thatappropriate fastener inserts 50 can then be installed therein.

In some aspects, a registration arrangement 1300 may be operably engagedwith one or both of the frame members 320, 340. In general, theregistration arrangement 1300 may be configured to interact with thecomposite panel 75 such that the composite panel 75 is registered withrespect to the first coordinate system 1200 upon being secured by theframe members 320, 340 in the closed position. In one example, either orboth of the frame members 320, 340 may be configured such that, uponreceipt of the composite panel 75 therebetween, the composite panel 75interacts with an alignment provision (i.e., a mechanical guide) of theregistration arrangement 1300 configured to engage one or more featuresof the composite panel 75 upon insertion thereof, which therebyautomatically aligns the composite panel 75 with the first coordinatesystem 1200 with respect to the origin 1100 thereof.

In other instances, the registration arrangement 1300 may be configuredto examine the composite panel 75 secured by the frame members 320, 340,and determine therefrom the relationship of the secured composite panel75 to the first coordinate system 1200. For example, the registrationarrangement 1300 may comprise an image acquisition device (i.e., adigital camera) in communication with a computer device 1500. Images ofthe secured composite panel captured by the image acquisition device maybe directed to the computer device 1500, and features of the compositepanel determined by image analysis/machine vision processing. The origin1100 and the first coordinate system 1200 may thus be registered withthe analyzed image of the composite panel 75 to align the compositepanel with the first coordinate system 1200.

Registration of the composite panel 75 with the first coordinate system1200 may be implemented by the fastener insert installation system 100with regard to installing fastener inserts 50 in correspondinginsert-receiving orifices 25 defined by the composite panel 75. That is,the fastener insert installation system 100 may be configured todetermine the locations of the insert-receiving orifices 25 in thecomposite panel 75, according to the first coordinate system 1200, inorder to implement an automated fastener insert installation process. Assuch, in some aspects, the composite panel 75 may have been previouslyprocessed upstream through a milling machine/device (not shown) to formthe insert-receiving orifices 25 in either or both of the major surfaces75A, 75B of the composite panel 75. In forming the insert-receivingorifices 25, the milling machine (i.e., a CNC-programmed millingmachine) may implement machine code detailing the parameters associatedwith the orifices 25. For instance, the machine code may include detailsrelated to the locations/coordinates of the orifices 25 in relation to acoordinate system (i.e., a “second coordinate system”) associated withthe composite panel 75, as well as, for example, the configuration ofeach orifice (i.e., whether a through-hole configuration or a blind holeconfiguration) and the size (i.e., lateral size or longitudinal size) ofeach orifice.

Since at least some of this same information included in the machinecode is required by the automated fastener insert installation process,aspects of the present disclosure provide that the computer device 1500is configured to receive or read the machine code implemented by theprevious upstream milling machine (i.e., the CNC milling program) forthe composite panel 75 subsequently received by the panel handlingmodule 300 of the fastener insert installation system 100. That is, insome aspects, the computer device 1500 or the registration arrangement1300 associated therewith may be configured such that the firstcoordinate system 1200 corresponds with the second coordinate systemused by the upstream milling machine. As such, upon the first and secondcoordinate systems being associated by the computer device1500/registration arrangement, a programming output from the millingmachine program code may be used to create fastener insertion data fordriving the fastener insert installation process, for example, byallowing the computer device 1500 to identify the insert-receivingorifices 25 and categorize the orifices 25 according to configuration,size, and coordinates (location) with respect to the composite panel 75or the identified origin 1100 associated therewith. On this basis, thecomputer device 1500 may be configured to specify the fastener insertconfiguration (i.e., type) or size or other specification forinstallation in each orifice 25, an efficient order of installation ofthe fastener inserts 50 across either or both major surfaces 75A, 75B ofthe composite panel 75, and, if necessary, may move or adjust any of thesupports 360 engaged with the frame member(s) 320, 340 so as to assureexternal access to the orifices 25 for fastener insert installation.

In order to ascertain that the composite panel 75 received by the panelhandling module 300 corresponds to the milling machine program codereceived by the computer device 1500, the panel handling module 300 mayimplement certain panel identification measures to minimize or eliminatethe risk of an improper fastener insert installation process occurringwith the composite panel 75. For example, general identification of thecomposite panel 75, and information associated with the configuration ofeach insert-receiving orifice 25 therein, the size of eachinsert-receiving orifice 25 therein, and/or the coordinates of eachinsert-receiving orifice 25 in the second coordinate system may beincorporated into a coded indicium (i.e., a bar code or other machinereadable code) 1550 associated with the composite panel 75. In suchinstances, the computer device 1500 or registration arrangement 1300 mayfurther include a code reader device 1600 configured to read the codedindicium 1550 associated with the particular composite panel 75 receivedand secured between the frame members 320, 340 and to communicate thegeneral identification information and at least information associatedwith the coordinates of the insert-receiving orifice in the secondcoordinate system to the computer device 1500/registration arrangement1300 for association with the first coordinate system 1200.Implementation of the image acquisition device and/or the code readerdevice 1600 may further allow a feedback loop or system to beimplemented by the computer device 1500 to ascertain, for example, thatthe same software revision and/or revision of the product specificationfor the particular composite panel 75 was/is being implemented by theupstream milling machine, as well as the fastener insert installationsystem 100. The information processed in the feedback loop may thusfacilitate and ensure, for instance, that the correct fastener insert 50is being installed in the particular orifice 25, that the correct sizeof the fastener insert 50 is being selected for the diameter of theorifice 25 or the depth of the composite panel 75, or that any supports360 associated with the frame member 320, 340 are not impeding access toany of the orifices 25 receiving a fastener insert 50.

The fastener insert assembly module or system 700 as shown, for example,in FIG. 3, is configured to engage each of a plurality of fastenerinserts 50 with an installation aide 45. As shown in FIGS. 5A and 5B, afastener insert 50 for composite panels 75, as disclosed herein,generally includes a body portion 62, an engagement end 64 engaged withone end of the body portion 62, and a retention end 66 engaged with theother end of the body portion 62. FIGS. 5A and 5B schematicallyillustrate two example fastener inserts 50, wherein the fastener insert50 illustrated in FIG. 5A has a “blind hole” configuration, and thefastener insert 50 illustrated in FIG. 5B has a “through hole”configuration. The engagement end 64 of the fastener insert 50 defines aplurality of adhesive application orifices 65 extending therethroughfrom an engagement surface 68 of the engagement end 64, distal to thebody portion 62. When installed in the insert-receiving orifice 25 ofthe composite panel 75, the fastener insert 50 is preferably disposedsuch that the engagement surface 68 is as close to flush with the one ofthe major surfaces 75A, 75B defining the orifice 50, as possible (i.e.,within a tolerance of about 0.005 inches). As such, it may be desirableto support the fastener insert 50 within the orifice 25 such that theengagement surface 68 is as close to flush as possible with the majorsurface of the composite panel 75, while an adhesive material isdirected through the adhesive application orifices 65 and into theinsert-receiving orifice 25 about the body portion 62 of the fastenerinsert 50, wherein the adhesive material, upon curing, interacts betweenthe fastener insert 50 and the portion of the composite panel 75defining the insert-receiving orifice 25 to retain and secure thefastener insert 50 therein. In order to support the fastener insert 50in the desired position within the orifice 25, an installation aide 45(i.e., a temporary planar tab having a lateral dimension greater thanthe lateral dimension of the orifice 25) may be affixed to theengagement surface 68 of the fastener insert 50. As such, upon insertionof the fastener insert 50 in the orifice 25, the installation aide 45engages the major surface about the orifice 25 and supports theengagement surface 68 close to flush with the major surface, while theadhesive material is directed through the adhesive application orifices65 and about the fastener insert 50 within the orifice 25.

Since the fastener insert 50 must be assembled with the installationaide 45 prior to the fastener insert installation process, a furtheraspect of the present disclosure provides a fastener insert assemblymodule or system 700 which may initially be configured to sort thefastener inserts 50 by configuration (i.e., according to a through-holeinsert configuration or a blind-hole insert configuration) or size(i.e., according to a lateral size or a longitudinal size) thereof. Forexample, the fastener assembly module 700 may include three separatehoppers 710, 720, 730 for receiving three different configurations orsizes of fasteners inserts 50. In one instance, one hopper 710 mayreceive a first configuration/size of a through hole insert, a secondhopper 720 may receive a second configuration/size of a through holeinsert, and a third hopper 730 may receive a first configuration/size ofa blind-hole insert. An alignment provision may be associated with eachhopper 710, 720, 730 such that respective fastener inserts 50 fedtherethrough are aligned with respect to each other (i.e., such that thelongitudinal axes of the fastener inserts 50 are parallel to eachother).

A fastener insert manipulation device 750 (i.e., a robotic arm) asshown, for example, in FIG. 3, is configured to select from among thesorted and aligned fastener inserts 50, and to manipulate the selectedfastener insert 50 so as to engage the engagement surface 68 of thefastener insert 50 with an engagement surface 47 of an installation aide45. The installation aides 45 may be affixed (i.e., by a temporaryadhesive) to an elongate sheet material 760 in a serial manner, whereinthe sheet material 760 can then be wrapped about a roll. The rolledsheet material 760 may be fed to an interaction location so that theinstallation aides 45 engaged therewith are sequentially presented suchthat the engagement surface 47 thereof is exposed for interaction withone of the fastener inserts 50. The engagement surface 47 may have anadhesive material (i.e., a temporary adhesive) engaged therewith. Sinceeach fastener insert 50 defines a plurality of adhesive applicationorifices 65 spaced apart about the engagement surface 68, and since eachinstallation aide 45 defines a plurality of adhesive applicationorifices 40 spaced apart about an engagement surface 47 thereof, thefastener insert manipulation device 750 may also be configured to alignthe adhesive application orifices 65 of each fastener insert 50 withcorresponding adhesive application orifices 40 of the installation aide45.

Such alignment of the adhesive application orifices 65, 40 may beaccomplished, for example, by a machine vision/feedback system (notshown) in communication with the fastener insert manipulation device750. The machine vision/feedback system may be configured to guide thefastener insert manipulation device 750 to orient the fastener insert 50selected thereby, until the adhesive application orifices 65 thereofcorrespond and align with the adhesive application orifices 40 of theinstallation aide 45 at the interaction location. Once the adhesiveapplication orifices 65, 40 of the fastener insert 50 and theinstallation aide 45 are aligned, the fastener insert manipulationdevice 750 causes the engagement between the engagement surfaces 68, 47.The fastener insert manipulation device 750 then moves the fastenerinsert 50, now engaged with the installation aide 45, away from theinteraction location such that the installation aide 45 is removed fromadherence to the sheet material. The fastener insert manipulation device750 is subsequently configured to orient each fastener insert engagedwith one of the installation aides into an insertion orientationrelative to the installation aide, and to store the fastener insert suchthat no external forces are exerted on the interface between thefastener insert 50 and the installation aide 45 that could causemisalignment between the adhesive application orifices 65, 40. In someinstances, a fastener insert supply device 800 may be configured toreceive the fastener inserts 50, each engaged with respectiveinstallation aides 45, from the fastener insert manipulation device 750,with the fasteners inserts 50 oriented in the insertion orientationrelative to the installation aide 45 and sorted according to theconfiguration or the size thereof. For example, the fastener insertsupply device 800 may comprise a series of conveyors 820, 840, 860 eachconfigured to store and serve as a staging area for the differentfastener insert/installation aide configurations or sizes, wherein aselected one of the fastener insert/installation aide assembly isalready oriented for insertion into the insert receiving orifice 25 inthe composite panel 75, and wherein the opportunities for misalignmentof the fastener insert/installation aide assemblies between each other,as well as misalignment between the fastener insert 50 and theinstallation aide 45, are limited or minimized.

As previously disclosed, typical fastener inserts 50 of the types hereinmay often be installed in the composite panel 75 using a special purposetwo-part potting compound as an adhesive material. However, such aspecial purpose potting compound may include, for example,weight-reducing glass microspheres, which typically require carefulhandling to avoid damage to the microspheres. As such, bulk mixing anddispensing provisions may not necessarily be desirable or appropriatefor such types of adhesive materials. In addition, once actuated bymixing the two parts of the potting compound, the actuated adhesivematerial has a limited time in which it can be applied (i.e., on theorder of 12 minutes maximum application life), and thus the amount ofthe actuated adhesive material that can be dispensed in connection withthe fastener insert installation process is likewise limited. In suchinstances, one practical solution may be mixing and dispensing smallbatches of the potting compound, and timing the mixing of a series ofsmall batches to optimize the dispensation of the actuated adhesivematerial during the fastener insert installation process.

The adhesive material preparation module or system 500 as shown, forexample, in FIG. 4, may thus be configured to receive one or moreadhesive material kits 550, for example, of the type shown in FIG. 6,and to mix and actuate the adhesive material therein. As illustrated,each adhesive material kit 550 may comprise a tubular body 560 havingthe two components of the adhesive material therein separated by amembrane (not shown). A plunger/mixer 570 extends longitudinally outwardfrom the tubular body 560. In order to actuate the adhesive material,the plunger/mixer 570 is urged longitudinally with respect to thetubular body 560 so as to rupture the membrane and introduce the twoparts of the potting compound to each other within the tubular body 560.The plunger/mixer 570 may be subsequently rotated about the longitudinalaxis and simultaneously translated along the longitudinal axis such thatthe two parts of the potting compound are thoroughly mixed and theadhesive material actuated (which starts the timing of the applicationlife of the actuated adhesive material). Removal of the plunger/mixer570 from the tubular body 560, following the actuation of the adhesivematerial therein, leaves a dispensation opening (not shown) in thetubular body 560 through which actuated adhesive material is dispensed.

The adhesive material preparation module 500 may be configured toinclude a supply device 600 for receiving un-actuated adhesive materialkits 550 in a suitable arrangement for providing a continuous supply foruse in the fastener insert installation process, with each kit 550 beingin a suitable orientation for selection by a manipulation device 625(i.e., a robotic arm) controlled by a controller device (i.e., thecomputer device 1500 or other appropriate computer device). Uponselection of a kit 550 from the supply device 600, the kit is moved to amixing device 650, wherein the kit 550 is then processed to actuate theadhesive material therein. The kit 550 having the actuated adhesivematerial is then delivered to the fastener insert installation module900 for use in the fastener insert installation process. In this regard,as previously disclosed, the actuated adhesive material in a kit 550 mayhave an effective application lifetime on the order of about 11 or 12minutes. As such, the actual working time in which a kit 550 may be usedto dispense the actuated adhesive material may be on the order of about7 or 8 minutes in order, for instance, to produce a suitable margin ofeffectiveness before the actuated adhesive material proceeds to cure.The adhesive material preparation module 500 may thus also be configuredto prepare a subsequent adhesive material kit 550 for mixing andactuation of the adhesive material therein prior to expiration of theworking time of the actuated adhesive material in a previous adhesivematerial kit 550.

Due to the sensitive timing requirements involved with the use of theadhesive material kits 550, the adhesive material preparation module 500may also be configured to monitor the operational time for each kit 550.In this regard, the adhesive material preparation module 500 may also bein communication with the controller device for control and/ormonitoring thereof. In regard to the timing of the kits 550, a timestamp may be associated with a kit 550 upon actuation of the adhesivematerial within the kit 550 at the mixing device 650, for example, byscanning a coded indicium (i.e., a bar code) associated with the kit 550and initiating a timer limited to a predetermined working time, whichmay be, but is not necessarily, less than the effective applicationlifetime of the actuated adhesive material in the kit 550. Uponexpiration of the working time, the kit 550 is recalled by thecontroller, recovered and discarded, and replaced with a subsequent kit550 having actuated adhesive material therein and subject to the sametime stamp limitations as the previous kit 550.

It may be possible that the dispensation of the actuated adhesivematerial from a kit 550 causes the actuated adhesive material in thatkit 550 to be exhausted prior to the expiration of the working time. Assuch, in some instances, each kit 550 may be monitored by the controllerdevice, either directly or indirectly, to determine the amount of theactuated adhesive material dispensed or the amount of the actuatedadhesive material remaining. Direct monitoring may be accomplished, forexample, with an appropriate sensor in communication with the computerdevice 1500. Indirect monitoring may be accomplished, for example,through analysis of the order and the configurations of the fastenerinserts and the installation rate of the fastener insert installationprocess for a particular composite panel 75 to determine usage of theactuated adhesive material in a kit 550 in comparison to the workingtime limit. In any event, the adhesive material preparation module 500is configured to minimize process down time upon the expiration of acurrent kit 550 by way of the controller determining that expiration ofthe current kit 550 and directing the adhesive material preparationmodule 500 (i.e., the manipulation device 625 and the mixing device 650)to prepare a subsequent kit 550 for deployment at an appropriate timeafter the expired kit 550 is recovered and discarded.

The fastener insert installation module or device 900 as shown, forexample, in FIG. 2, may be engaged with or disposed in proximity to thepanel handling module 300, and may include an analysis device 925configured to determine a configuration or a size of theinsert-receiving orifice 25 defined by and extending through a majorsurface of the composite panel 75 received and secured by the panelhandling module 300. A manipulation device 950 is in communication withthe analysis device 925 and is configured to select and retrieve one ofthe plurality of fastener inserts 50 engaged with the installation aide45, in response to the configuration or the size of the insert-receivingorifice 25 determined by the analysis device 925. The manipulationdevice 950 is also configured to deliver the selected fastener insert 50to a fastener installation/adhesive dispenser device 975 configured toinsert the selected fastener insert 50 into the insert-receiving orifice25 such that the installation aide 45 engages the major surface 75A, 75Bof the composite panel 75. The fastener installation/adhesive dispenserdevice 975 is further configured to dispense the actuated adhesivematerial from the adhesive material kit 550 and through the adhesiveapplication orifices 65, 40 defined by the installation aide 45 and theselected fastener insert 50, and into the insert-receiving orifice 25about selected fastener insert 50, such that the actuated adhesivematerial interacts with the selected fastener insert 50 and thecomposite panel 75 defining the insert-receiving orifice 25 so as tosecure the selected fastener insert 50 within the insert-receivingorifice 25 upon curing of the actuated adhesive material. Themanipulation device 950 may also be configured to retrieve an adhesivematerial kit 550 from the adhesive material preparation module 500,deliver the kit 550 to the fastener installation/adhesive dispenserdevice 975, and recover the kit 550 from the fastenerinstallation/adhesive dispenser device 975 and discard the kit 550 uponexpiration thereof.

Initially, the analysis device 925 is configured to inspect thecomposite panel 75 secured by the panel handling module 300 to determineor confirm whether the insert-receiving orifice 25 defined by thecomposite panel 75 was formed in a through-hole configuration or ablind-hole configuration, and/or determine or confirm a location, alateral size (i.e., diameter) or a longitudinal size (i.e., thethickness of the composite panel 75) of the insert-receiving orifice 25.In making such determinations or confirmations, the analysis device 925may implement, for example, machine vision, laser measurements, or thelike. In some instances, the analysis device 925 may be in communicationwith the computer device 1500. In such instances, the configuration,size, and/or coordinates (location) of the insert-receiving orifice(s)25 defined by and extending through a major surface of the compositepanel 75 received and secured by the panel handling module 300, mayalready be known by way of the machine code received from the priorupstream milling process. Accordingly, the information gathered by theanalysis device 925 may serve to verify or confirm the informationincluded in the machine code from the upstream milling process.

Once the parameters of the insert-receiving orifice 25 have beendetermined or confirmed by the analysis device 925, the manipulationdevice 950 is directed to retrieve one of the fastener inserts 50 of theappropriate configuration and size (and having the installation aide 45engaged therewith) from one of the series of conveyors 820, 840, 860(staging area) of the fastener insert supply device 800 of the fastenerinsert assembly module 700, and to deliver the selected fastener insert50 in an appropriate orientation to the fastener installation/adhesivedispenser device 975 for installation in the composite panel 75. Theinstallation aide 45 engaged with the selected fastener insert 50 mayinclude an adhesive material (i.e., a temporary adhesive) on theengagement surface 47 thereof engaging engagement surface 68 of thefastener insert 50. The fastener installation/adhesive dispenser device975 is further configured to insert the selected fastener insert 50 intothe insert-receiving orifice 25, for instance, such that the fastenerinsert 50 is centered within the orifice 25. Upon insertion of thefastener insert 50 into the orifice 25, the portion of the engagementsurface 47 exceeding the lateral dimension of the engagement end 64 ofthe fastener insert 50 engages and adheres, via the adhesive material,to the major surface 75A, 75B of the composite panel 75 defining theinsert-receiving orifice 25. In this manner, the installation aide 45secures the fastener insert 50 in a desired position within the orifice25, and supports the engagement surface 68 of the fastener insert 50substantially flush with the major surface 75A, 75B or the compositepanel 75.

The manipulation device 950 may also be configured to retrieve anadhesive material kit 550 containing the actuated adhesive material(i.e., potting compound) from the adhesive material preparation module700, and to deliver the kit 550 to the fastener installation/adhesivedispenser device 975. The fastener installation/adhesive dispenserdevice 975 is further configured to align the dispensation opening ofthe tubular body 560 of the kit 550 with each adhesive applicationorifice 40, 65 extending through the installation aide 45 and theengagement end 64 of the fastener insert 50, in turn. For each adhesiveapplication orifice 40, 65, the actuated adhesive material is dispensedfrom the kit 550 by the fastener installation/adhesive dispenser device975 by reducing the volume of the tubular body 560 of the adhesivematerial kit 550. For example, the tubular body 560 may include amovable end plate (not shown) engaged therewith opposite to thedispensation opening, wherein the fastener installation/adhesivedispenser device 975 may be configured to move the end plate toward thedispensation opening along the tubular body 560 in order to reduce thevolume within the tubular body 560 and dispense the actuated adhesivematerial through the dispensation opening. The dispensed actuatedadhesive material enters the insert-receiving orifice 25 about the bodyportion 62 of the fastener insert 50 and is sufficiently viscous so asto flow to fill the space between the fastener insert 50 and the portionof the composite panel 75 defining the orifice 25 (i.e., the honeycombmaterial structure). In some instances, the actuated adhesive materialis dispensed until a certain excess amount or overfill flows backoutwardly of the particular adhesive application orifice 40, 65, atwhich time the fastener installation/adhesive dispenser device 975ceases dispensing the actuated adhesive material from the kit 550. Insome instances, the appropriate excess amount realized through theadhesive application orifice 40, 65 before ceasing the dispensation ofthe actuated adhesive material may be determined, for example, by theanalysis device 925 using machine vision. For example, it may bespecified that a sufficient amount of the actuated adhesive material hasbeen dispensed into the orifice 25 about the fastener insert 50 when anadhesive overflow of about 0.25 inches long is detected and determinedby the analysis device 925.

Due to the viscous nature of the actuated adhesive material, thedispensation opening of the adhesive material kit 550 may remain incontact with the dispensed actuated adhesive material when the fastenerinstallation/adhesive dispenser device 975 is directed to ceasedispensation. In some instance, the fastener installation/adhesivedispensation device 975 may be further configured to exert a negativepressure on the actuated adhesive material, upon dispensation of aselected amount of the actuated adhesive material from the adhesivematerial kit 550, in order, for example, to retract excess actuatedadhesive material from the dispensation opening back into the tubularbody 560 of the adhesive material kit 550. That is, for instance, thefastener installation/adhesive dispenser device 975, upon being directedto cease dispensation of the actuated adhesive material from the kit550, may retract the end plate of the kit 550 away from the dispensationopening by a predetermined amount so as to expand the effective volumeof the tubular body 560 and exert a negative pressure on the actuatedadhesive material about the dispensation opening. In such instances, theapplication of the negative pressure may break the flow of the actuatedadhesive material from the dispensation opening and provide a cleanertail end of the dispensed actuated adhesive material and/or the excessamount/overflow associated therewith. The break of the actuated adhesivematerial may be further facilitated, in some instances, by the fastenerinstallation/adhesive dispenser device 975 moving the dispensationopening of the kit 550 away from the adhesive application orifice 40, 65concurrently with the application of the negative pressure of the kit550. Some results of this procedure may be, for instance, a cleanerdispensation opening of the kit 550 for subsequent dispensing of theactuated adhesive material therefrom and/or preventing contamination ofthe composite panel 75 from excess adhesive material.

Once the dispensation process for one of the adhesive applicationorifices 40, 65 is completed, the fastener installation/adhesivedispenser device 975 is configured to move the dispensation opening ofthe kit 550 to each of the adhesive application orifices 40, 65, inturn, until all such adhesive application orifices 40, 65 are determinedto demonstrate the specified overflow amount of the actuated adhesivematerial. As previously disclosed, in some instances, the fastenerinsert installation module 900 or a component thereof may be configuredto limit dispensation of the actuated adhesive material from theadhesive material kit 550 to within a predetermined working time, or tootherwise monitor the dispensation of the actuated adhesive materialfrom a kit, and to direct the current kit 550 to be replaced with asubsequent kit 550 upon expiration of the current kit 550. Once thefastener insert installation process is completed and the adhesivematerial is cured, the installation aides 45 can be removed from thecomposite panel 75 by dissolving or otherwise negating the adhesivematerial securing the installation aide 45 to the major surface 75A,75B, along with removing any excess/overflow amounts of the curedadhesive material extending outwardly of the adhesive applicationorifices 40, 65.

Many modifications and other aspects of the disclosures set forth hereinwill come to mind to one skilled in the art to which these disclosurespertain having the benefit of the teachings presented in the foregoingdescriptions and the associated drawings. Therefore, it is to beunderstood that the disclosures are not to be limited to the specificaspects disclosed and that equivalents, modifications, and other aspectsare intended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

That which is claimed:
 1. An automated fastener insert installationsystem for use in a composite panel fastener insert installationprocess, comprising: an adhesive material preparation system, including:a mixing device arranged to mix and actuate the adhesive material in anadhesive material kit; and a manipulation device arranged to direct theadhesive material kit to the mixing device and to direct the adhesivematerial kit having the mixed and actuated adhesive material thereinfrom the mixing device for dispensation of the mixed and actuatedadhesive material from the adhesive material kit.
 2. The system of claim1, comprising a controller in communication with and arranged to directthe manipulation device to recover the adhesive material kit having themixed and actuated adhesive material therein upon expiration of apredetermined working time following mixing and actuation of theadhesive material.
 3. The system of claim 2, wherein the controller isarranged to direct the manipulation device and the mixing device toprepare a subsequent adhesive material kit for mixing and actuation ofthe adhesive material therein prior to expiration of the working time ofthe actuated adhesive material in a previous adhesive material kit. 4.The system of claim 1, wherein the controller is arranged to monitordispensation of the actuated adhesive material from the adhesivematerial kit with respect to a predetermined working time followingmixing and actuation of the adhesive material, and to direct themanipulation device and the mixing device to prepare a subsequentadhesive material kit for mixing and actuation of the adhesive materialtherein prior to an earlier occurrence of exhaustion of the actuatedadhesive material from dispensation thereof or expiration of thepredetermined working time of the actuated adhesive material, within aprevious adhesive material kit.
 5. The system of claim 4, wherein thecontroller is arranged to monitor for exhaustion of the actuatedadhesive material by determining an amount of the actuated adhesivematerial dispensed from the adhesive material kit or by determining anamount of the actuated adhesive material remaining in the adhesivematerial kit.
 6. The system of claim 4, wherein the controller isarranged to direct the manipulation device to recover the adhesivematerial kit having the mixed and actuated adhesive material thereinupon exhaustion of the actuated adhesive material from dispensationthereof.
 7. The system of claim 1, wherein the adhesive material kitincludes a multiple-part adhesive compound, the multiple parts of theadhesive compound, when mixed, forming the actuated adhesive material.8. The system of claim 7, wherein the multiple-part adhesive compoundcomprises a two-part potting compound.
 9. The system of claim 1, whereinthe adhesive material kit includes a tubular body having two componentsof the adhesive material therein separated by a membrane, and a mixerextending into the tubular body, and wherein the mixing device isarranged to urge the mixer along a longitudinal axis with respect to thetubular body so as to rupture the membrane and introduce the twocomponents of the adhesive material to each other within the tubularbody, the mixing device being further arranged to rotate the mixer aboutthe longitudinal axis and to simultaneously translate the mixer alongthe longitudinal axis such that the two components of the adhesivematerial are mixed and the adhesive material actuated.
 10. The system ofclaim 9, wherein the mixing device is arranged to remove the mixer fromthe tubular body following the actuation of the adhesive materialtherein, so as to form a dispensation opening in the tubular body, theactuated adhesive material being dispensable through the dispensationopening.
 11. A method of providing an adhesive material in a compositepanel fastener insert installation process implemented in an adhesivematerial preparation system of an automated fastener insert installationsystem, the method comprising: mixing and actuating the adhesivematerial in an adhesive material kit using a mixing device; directingthe adhesive material kit to the mixing device using a manipulationdevice; and directing the adhesive material kit having the mixed andactuated adhesive material therein, using the manipulation device, fromthe mixing device for dispensation of the mixed and actuated adhesivematerial from the adhesive material kit.
 12. The method of claim 11,comprising directing the manipulation device, using a controller incommunication therewith, to recover the adhesive material kit having themixed and actuated adhesive material therein upon expiration of apredetermined working time following mixing and actuation of theadhesive material.
 13. The method of claim 12, comprising directing themanipulation device and the mixing device, using the controller incommunication therewith, to prepare a subsequent adhesive material kitfor mixing and actuation of the adhesive material therein prior toexpiration of the working time of the actuated adhesive material in aprevious adhesive material kit.
 14. The method of claim 11, comprisingmonitoring, using the controller, dispensation of the actuated adhesivematerial from the adhesive material kit with respect to a predeterminedworking time following mixing and actuation of the adhesive material;and directing the manipulation device and the mixing device to prepare asubsequent adhesive material kit for mixing and actuation of theadhesive material therein prior to an earlier occurrence of exhaustionof the actuated adhesive material from dispensation thereof orexpiration of the predetermined working time of the actuated adhesivematerial, within a previous adhesive material kit.
 15. The method ofclaim 14, comprising monitoring, using the controller, for exhaustion ofthe actuated adhesive material by determining an amount of the actuatedadhesive material dispensed from the adhesive material kit or bydetermining an amount of the actuated adhesive material remaining in theadhesive material kit.
 16. The method of claim 14, comprising directingthe manipulation device, using the controller, to recover the adhesivematerial kit having the mixed and actuated adhesive material thereinupon exhaustion of the actuated adhesive material from dispensationthereof.
 17. The method of claim 11, wherein the adhesive material kitincludes a multiple-part adhesive compound, and wherein mixing andactuating the adhesive material in an adhesive material kit comprisesmixing the multiple parts of the adhesive compound such that the mixedmultiple parts form the actuated adhesive material.
 18. The method ofclaim 17, wherein the multiple-part adhesive compound comprises atwo-part potting compound.
 19. The method of claim 11, wherein theadhesive material kit includes a tubular body having two components ofthe adhesive material therein separated by a membrane, and a mixerextending into the tubular body, and wherein mixing and actuating theadhesive material in an adhesive material kit comprises urging the mixeralong a longitudinal axis with respect to the tubular body, using themixing device, so as to rupture the membrane and introduce the twocomponents of the adhesive material to each other within the tubularbody; and rotating the mixer about the longitudinal axis andsimultaneously translating the mixer along the longitudinal axis, usingthe mixing device, such that the two components of the adhesive materialare mixed and the adhesive material actuated.
 20. The method of claim19, comprising removing the mixer from the tubular body, using themixing device, following the actuation of the adhesive material therein,so as to form a dispensation opening in the tubular body, the actuatedadhesive material being dispensable through the dispensation opening.